Decorative panel and method of producing a decorative panel

Abstract

The invention relates to a method of producing a decorative panel and to such panel. The decorative panel (100) is in particular a floor panel, cladding panel, wall panel or ceiling panel and comprises at least one substrate (101) comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern (102), wherein the substrate is a primed substrate comprising a primer layer (103); a finishing layer, comprising at least one primary coating layer (104); and at least one secondary coating layer (105); wherein the finishing layer comprises a surface structure; and wherein the surface roughness (Ra) of the at least one finishing layer is at least 4 µm, and wherein the at least finishing layer has a hardness of at least 75 Shore D. The method of producing the decorative panel includes the steps of texturing the primary coating layer by means of a texturing medium and / or a mask, and texturing the secondary coating layer by means of a secondary texturing medium and / or a secondary mask.

Description

[0001] Decorative panel and method of producing a decorative panel

[0002] The invention relates to a method of producing a decorative panel comprising a textured finishing layer. The invention also relates to a decorative panel.

[0003] Traditional methods of structuring the surface of decorative panels not comprising a wear layer, while commonly employed, suffer from several limitations that impact the quality, realism, and durability of the final product. These methods typically involve pressing a structured element, such as a roller or embossing die, onto a material sheet coated with uncured lacquer prior to curing. While this approach can create a limited surface texture, it presents several technical drawbacks. One significant limitation is the difficulty in achieving controlled variation in depth across the embossed pattern, especially with hot press treatments that deform. Traditional methods result in a shallow, uniform texture depth, producing textures that look artificial and fail to capture the nuanced tactile experience of natural materials. This is particularly problematic when mimicking materials like wood or stone, where subtle variations in depth are crucial to achieve a realistic visual effect.

[0004] Furthermore, limitations in absolute depth using these traditional methods, which is limited to a total thickness of the applied liquid lacquer, can restrict the overall three-dimensionality and visual impact of the embossed design, as the lack of a variety of texture depth, or possible texture depth, results in an undesirable visual flatness that lacks the depth of a more varied haptic design. Furthermore, aligning the embossed pattern with the decorative design of the panel, such as a printed wood grain, proves challenging with traditional methods. This misalignment further diminishes the intended aesthetic effect. Furthermore, the inherent brittleness of conventional lacquer layers presents a further challenge, as after curing, these lacquer layers are prone to cracking or unevenness, especially when subjected to the stresses of the embossing process. This is further exacerbated in panels where the materials themselves may not provide adequate support, potentially leading to delamination of the layers, insufficient scratch resistance, and a compromised final product. Lastly, conventional electromagnetically cured lacquer layers are prone to volumetric shrinking during the polymerization process, causing stresses within the panel resulting in its undesired bending, warping and cupping when exposed to heat. This combination of limitations of traditional methods in producing decorative panels prevents consistent quality, realistic textures, and long-term durability.The durability of decorative embossing patterns is a significant concern affecting the lifespan and aesthetic appeal of panels, particularly in high-traffic environments. The raised areas of these embossed textures are inherently prone to abrasion, gradually wearing down and resulting in a loss of definition and a flattened appearance over time. This wear is exacerbated by inconsistent application of the embossing layer, often due to uneven pressure during the manufacturing process, leading to poor adhesion and weak points in the pattern. Exposure to moisture and temperature fluctuations further compromises the structural integrity of the surface textures. Moisture can penetrate the material, causing swelling and distortion, while temperature changes lead to expansion and contraction, weakening the bond between the embossing layer and the substrate. This can result in cracking, peeling, and a general degradation of the embossed design. Therefore, creating decorative panels with durable embossing that can withstand wear, retain their quality, and resist environmental factors is a considerable challenge, particularly across various substrate materials.

[0005] Structuring the surface of a decorative panel typically involves processes to pattern or texture material sheets, such as those printed or coated with lacquer or resin-soaked paper. In such process, the uppermost layer of uncured lacquer or resin is brought into contact with a structured roller, press plates, or press rollers.

[0006] Subsequently, the lacquer or resin hardens, resulting in a three-dimensional surface texture by curing. This curing can occur via heat or radiation passing through an embossing die. After curing, the embossing die is removed from the panel, leaving the cured resin or lacquer with a structure mirroring the negative image of the embossing die's surface texture. It is a pertinent issue for hot press treatments of decorative panels to have uniform depths, such that a levelled embossing is demonstrated throughout the panel, limiting the structural depths of a finish thus providing a haptic appeal that is less realistic. Likewise, conventional hot press treatments do not achieve embossing in register due to difficulties in the alignment of a structured pattern over a decorative design. Similar problems arise in mechanical embossing of surface textures particularly on non-plastic or, more particularly, non-PVC decorative panels due to potential delamination of lacquer and / or coating layers. This degrades the quality of embossing or embossing transfer on the decorative panel, such as imprinting a texture on a coating layer. After the lacquer layer is cured, there are tendencies for unevenness of theembossing and / or structured surface due to the brittleness of conventional lacquer layers.

[0007] It is therefore an object of the invention to solve at least some of the disadvantages of the prior art. The invention provides thereto a panel comprising a finishing layer with a surface texture having a varied depth of (tactile) pattern and a method for producing such panel.

[0008] The invention provides thereto a method of producing a (decorative panel), in particular a decorative floor, cladding, wall, or ceiling panel, comprising the steps of:

[0009] a) providing at least one substrate, the substrate comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern;

[0010] b) applying at least one at least partially uncured and / or partially cured primer, preferably a substantially transparent primer, upon at least part of the upper surface of the substrate thereby forming a primer layer and / or a primed substrate;

[0011] c) applying at least one uncured, or at least partially cured, primary coating upon at least part of the primed substrate, thereby forming at least one primary coating layer;

[0012] d) applying at least one texturing medium comprising at least one surface texture and / or at least one mask onto at least part of the at least one primary coating layer ;

[0013] e) at least partially curing at least part of the at least one primary coating layer such that a textured substrate is obtained;

[0014] f) removing the at least one texturing medium and / or at least one mask; g) applying at least one at least partially uncured, or at least partially cured, secondary coating upon at least part of the textured substrate, thereby forming at least one secondary coating layer;

[0015] h) optionally applying at least one secondary texturing medium comprising at least one secondary surface texture and / or at least one secondary mask onto at least part of the at least one secondary coating layer;

[0016] i) at least partially curing at least part of the at least one secondary coating layer; andj) optionally removing the at least one secondary texturing medium and / or at least one secondary mask.

[0017] The method according to the invention enables an accurate and effective way of producing decorative panels, in particular a decorative floor panels, cladding panels, wall panels or ceiling panels, which have a desired surface structure. The method has a high reproducibility resulting in panels with a consistent surface characteristics.

[0018] The method according to the invention provides for a panel having a surface roughness due to the applied surface texture(s). Said panel preferably comprises a substrate, most preferably a primed substrate. Said primed substrate is basically a substrate comprising at least one primer layer. The primer layer, the primary coating layer and / or the secondary coating layer may form a finishing layer. It is for example possible that the texturing medium and / or the secondary texturing medium enable that a surface roughness (Ra) of the at least one finishing layer is at least 4 pm and / or wherein the average maximum height (Rz) of at least part of the texture of the at least one finishing layer is at least 15 pm. Hence, the method according to the invention enables the production of a decorative panel wherein the surface roughness (Ra) of the at least one finishing layer is at least 4 pm and / or at most 25 pm, preferably in the range of about 5 pm to about 15 pm, and / or wherein the average maximum height (Rz) of at least part of the texture of the at least one finishing layer is at least 15 pm and / or at most 28 pm, preferably in the range of about 17 pm to about 25 pm. It has been found that at the above ranges of Ra and Rz, a realistic tactile perception and long-term functional durability of the finishing layer is achieved. In particular, a preferred embodiment having an Ra of at least 4 pm and an Rz of at least 15 pm provide a clearly perceivable micro-undulation and peak-to-valley relief that improves the haptic realism of the decorative pattern and contributes to functional performance such as slip resistance by increasing microinterlocking and reducing the tendency for a continuous water film to form. At the same time, limiting Ra to at most 25 pm and Rz to at most 28 pm reduces excessive peak formation that would otherwise be prone to accelerated abrasion and flattening, local stress concentrations, chipping / cracking of a hard topcoat, increased soil pickup, and reduced cleanability. This controlled range of surface roughness and average maximum height is difficult to achieve with conventionalembossing approaches where post-leveling of subsequently applied coatings and / or polymerization shrinkage of thick UV-curable lacquer layers tends to either flatten the texture or induce stresses that can lead to dimensional instability. The desired surface roughness and / or average maximum height of the texture can be obtained by applying a primary coating and a secondary coating sequentially to an upper surface of the panel and by texturing at least part of the at least one primary coating layer and / or the at least one secondary coating layer by applying at least one texturing medium. The (primary and / or secondary) texturing medium comprises at least one surface texture which is invertedly applied to the surface of the (uncured or partially uncured) coating layer. In an additional or alternative embodiment, the (primary and / or secondary) texturing medium comprises at least one mask which is configured to prevent curing of at least part of the (uncured or partially uncured) coating layer such that a surface texture is formed. Curing of at least part of the at least one coating layer is performed during and / or after the texturing step. The primer can be cured in the same step. Curing while the texturing medium and / or mask is still present is conceived to lock-in the transferred topography before reflow, elastic recovery or post-leveling occurs, thereby improving texture fidelity and making the resulting Ra / Rz more controllable and reproducible. Co-curing the primer in the same step can further improve interlayer adhesion by interdiffusion and / or coupled crosslinking at the interface between primer and coating, thereby reducing delamination risk during removal of the texturing medium and during service life. Moreover, coupled curing can reduced residual stress gradients due to shrinkage mismatch or thermal gradients and thereby reduces warping or cupping compared with thick UV-lacquer systems where polymerization shrinkage is concentrated in a single thick UV-curable layer. The at least one finishing layer may further have a coefficient of friction (COF) of at least about 0.4, slip resistance performances of at least P3 tested according to AS 4586, and / or a pendulum slip resistance (PTV) of the at least one coating layer is at least 36, preferably at least 61 according to ISO BS 7976-2.

[0019] It is beneficial that at least one at least partially uncured and / or partially cured primer, preferably a substantially transparent primer, is applied prior to at least one uncured, or at least partially cured, primary coating being applied. The primer layer is typically a dimensionally stable layer which does not exhibit a volumetric reduction during polymerization. The at least one texturing medium is preferablyconfigured such that a surface only extends into the at least one primary coating layer. In a preferred embodiment, the at least one texturing medium is configured such that at least part of a surface extends into the at least one primer layer. This surface is cured whilst the texturing medium is still applied upon the primary coating layer. The texturing medium may cover at least 80% of the primary coating layer. The texturing medium preferably covers the primary coating layer in full. After the curing step, the texturing medium is preferably removed. However, in a possible embodiment, it is conceivable that the texturing medium is removed prior to the curing steps. Hence, steps e) and f) may be reversed. It is also conceivable that steps i) and j), if applied, are reversed in order. In such embodiments, the at least one primary coating layer may already have been brought into a shape stable state by partial curing after step c) , such that the removal of the texturing medium prior to the main curing step does not substantially reduce texture fidelity.

[0020] In a further embodiment, the texturing step is configured such that the texturing medium is applied directly onto the at least partially uncured and / or partially cured primer layer, thereby forming a mechanical embossing within the primer layer itself. In this embodiment, the primer layer preferably comprises a crosslinkable resin, such as moisture-curable PUR, thermosetting PUR, acrylate resin, epoxy resin, and / or melamine-based resin, and is brought to a semi-cured and / or shape-stable state, such as by partial curing and / or rheological setting, prior to mechanical embossing, such that the primer layer can be embossed without cracking / whitening and such that the embossed geometry remains stable during the subsequent curing step. This embodiment is particularly suited where a resin-rich layer is intended to carry the mechanical embossing as the primary wear-providing surface.

[0021] Subsequently, a secondary coating may be applied upon the textured substrate. In a preferred embodiment, at least one secondary texturing medium comprising at least one secondary surface texture is applied onto at least part of the at least one secondary coating layer such that a secondary texture is provided. During the curing, the secondary texturing medium, if applied, remains upon the secondary coating layer. It is conceivable that the secondary texturing medium stabilizes fine features such as microtexture contributing to slip resistance during curing and reduces surface levelling, thereby preserving texture definition while the secondary coating achieves its final hardness and wear resistance.In some embodiments, the microtexture is provided by the texturing medium and / or pressing structure itself, such that the microroughness is transferred to the coating layer during the texturing step. In a further embodiment, the texturing medium and / or pressing structure comprises a microtexture formed by texturing particles, wherein at least part of the particles comprise carbon particles, oxide particles and / or ceramic particles, and / or combinations thereof. At least part of the texturing particles may have an average particle size of 0.5 to 10 pm, preferably 2-5 pm, in particular to provide controlled surface microroughness that reduces gloss. In such embodiment, the microtexture can be tuned differently for distal peak regions versus valley regions, for example by providing a higher concentration and / or larger particles at peak-defining parts of the macrotexture to increase or reduce gloss uniformityor variation at 60 or 85 degree angles. This embodiment is particularly suitable for low-gloss coated panels where gloss is a key aesthetic driver.

[0022] In a preferred embodiment, the secondary coating is selected and applied such that it does not substantially fill the valleys of the previously formed texture, for example by applying the secondary coating at a viscosity of at least 1 ,500 mPas, preferably at least 2,000 mPas, and / or at most 8,000 mPas at time of application, thereby balancing conformal coverage with reduced valley filling. This is in particular achieved by limiting application weight and thickness.

[0023] In a further embodiment, step g) of applying the secondary coating layer is omitted, such that the finishing layer comprises the primer layer and the primary coating layer, or in some embodiments only the primer / resin layer, wherein the uppermost cured layer is configured to provide the required durability and functional performance. In such embodiment, the primer / resin layer and / or the primary coating layer may be formulated as a crosslinked coating layer having a Shore D hardness of at least 85, preferably at least 90, and the substrate in particular the surface of the substrate preferably has a Shore D hardness of at least 80, thereby enabling that the surface does not deform into a soft underlying layer during localized pressure, reducing the risk of coating cracking that can visually appear as scratches. In this embodiment, the embossed resin layer itself serves as the final wear surface and no additional top coating is applied. Optionally, a relatively thin protective finishing layer may still be applied at a low coat weight (preferablybelow 15 g / m2, most preferably between 5 - 15 g / m2) for stain resistance, gloss, scratchresistance, and / or slip resistance purposes, without substantially filling or levelling the embossing. As an alternative method, the hardness of the finishing layer may be measured and expressed by ASTM D3363 and or ISO 1518. In a preferred embodiment, the hardness of the finishing layer is at least 2H when measured according to ASTM D3363 and / or at least 2200g when measured according to ISO 1518,

[0024] A benefit of the use of at least one texturing medium in the texturing step which is applied upon a(n) (uncured) coating layer and a(n) (uncured) secondary coating layer is that the at least one coating layer or the at least one coating layer and the at least one secondary coating layer can be performed in a controlled manner and results in the provision of a highly accurate textured surface pattern. The coating can for example be applied to the primed substrate panel via coating, spraying, brushing, deposition and / or combinations thereof. The secondary coating can for example be applied to the coated and primed substrate via coating, spraying, brushing, deposition and / or combinations thereof. The texturing step could also be referred to as an embossing step. The texturing medium transfers a 3D embossing or 3D texture into the coating layer, which can thereafter be at least partially cured. It is further conceivable that the texturing step of the at least one texturing medium extends into at least part of at least one transparent primer layer of the primed substrate.

[0025] When at least part of the texture of the coating layer and / or the secondary coating layer matches the decorative design of the panel the method according to invention can be classified as a co-called embossed-in-register manufacturing process (EIR). The use of an EIR texture results in the provision of artificial designs which have an authentic and / or natural appearance. It is for example possible that the applied surface texture matches a wood structure. The panel according to the present invention or obtained via the method according to the present invention typically comprises a tactile structure. The obtained EIR structure in the finishing layer is preferably in the form of a three-dimensional surface structure. During conventional methods, the structure is embossed in the panel surface by means of a three-dimensional structured (hot) press plate. During this process, the components of the coating that are activated by heat and pressure melt and run, thereby possibly filling out the three-dimensional structural embossing while curing. The number anddepth of the structures are limited by the available quantity of activated components on the one hand, and by the press force on the other. During conventional methods, the obtained EIR structure in the finishing layer is applied by means of a three-dimensional structured (hot) press plate and / or embossing roller. After this process, a liquid or semi-viscous coating may be applied, thereby at least partially filling out the three-dimensional structural embossing, severely limiting the visual effect of the embossing applied in the previous step. The method according to the present invention overcomes this problem as the use of the texturing medium after the application of at least one primer layer and / or at least one coating layer can enable controlled and accurate transfer of the texture and curing of the finishing layer. The coatings applied are not negatively affected by the texturing step and / or the texture is not negatively affected by the application of a coating. In a preferred embodiment, the coating layer(s) cover(s) at least 50%, preferably at least 75%, more preferably at least 90% of the upper surface of the panel. It is also conceivable that the upper surface of the panel is substantially entirely covered by at least one coating layer.

[0026] The primer is preferably a substantially transparent primer. It is conceivable that the at least one primer cures naturally. It is for example possible that curing occurs spontaneously through the chemical reaction of at least two components of the primer. It is preferred that the primer is not actively cured prior to the application of at least one coating layer. Maintaining the primer in a partially uncured or reactive state during application of the primary coating can promote interfacial bonding which improves peel strength and reduces delamination risk when the surface is mechanically textured and when the panel is subjected to thermal cycling.

[0027] Additionally, delaying the full cure of the primer can reduce internal stress build-up at the interface, which is beneficial for dimensional stability when compared to known art where a fully or at least partially cured brittle base layer is subsequently embossed. It is preferred that the primer maintains a certain level of viscosity prior to and / or during the application of at least one coating layer.

[0028] It is possible that the at least one primary coating and / or the at least one secondary coating is cured through exposure to electromagnetic radiation. The at least one primer layer, at least one primary coating layer and / or at least one secondary coating layer possibly comprises at least one abrasive additive selected from thegroup of aluminum oxide, corundum, quartz, silicon carbide, diamond particles, or any combination thereof. In a possible embodiment, the primary coating layer and / or the secondary layer comprises a plurality of abrasion resistant particles, in particular chosen from the group of aluminum oxide, corundum, silicon carbide, titanium dioxide, titanium oxide and / or diamond particles or diamond dust. It is conceivable that at least part of the abrasion resistant particles is dispersed in the primer layer, primary and / or secondary coating layer. In a further embodiment, the at least one primer layer, at least one primary coating layer and / or secondary coating layer may further comprise antimicrobial, antivirus, antibacterial and / or antifungal agents. The primer layer, primary and / or secondary coating layer may further comprise an antimicrobial agent that can be incorporated therein before the curing step. The antimicrobial agent embedded in the finishing layer, is conceived to be able to inhibit the emergence and / or growth of microbes such as fungus, bacteria (i.e. , gram positive and gram negative bacteria such as Staphylococcus aureus, Kleibsella pneumoniae and Salmonella and the like), yeast and other pathogens including nonpathogens on the surface of the floor panel.

[0029] In a further possible embodiment, the at least one decorative layer comprises a digital print layer and / or an inkjet-printed decorative layer provided on a ply of cellulose and / or a thermoplastic film. In this embodiment, the finishing layer comprises at least one resin-based layer configured to provide wear and scratch resistance without requiring a UV-cured acrylic aluminium oxide (AIOx) particle layer. This embodiment is particularly suited for digital-print product lines having multiple coating passes, as the resin-based primer layer can act as a durable foundation for embossing that further enables subsequent primary / secondary coating layers to be applied without substantially levelling the texture. The use of a primer layer according to the present invention instead of a UV-cured alox particle layer imparts improved dimensional stability to the panel, as the primer layer shows relatively low volumetric shrinking during curing in comparison to conventional acrylic alox particle layers,

[0030] In a further embodiment, the primer layer and / or the resin-based layer is selectively deposited in a spatially varying manner on the upper surface of the substrate, for example by an inkjet printhead, valve-jet, slot die with digitally controlled flow, or other digitally addressable dispensing system. The local deposition amount and / orlocal thickness is controlled based on a tactile map (height map) derived from the decorative pattern file, such that regions corresponding to pores, knots, veins, or grout lines receive a different primer / resin buildup than surrounding regions. This enables a digitally defined texture foundation that can be subsequently textured and / or cured to obtain an embossed-in-register (EIR) effect while reducing reliance on a conventional UV-cured acrylic AIOx particle layer. The selectively deposited primer / resin layer may subsequently be subjected to the texturing medium and curing steps described herein such that the resulting surface structure is formed and retained in a controlled manner.

[0031] The at least one primary coating as applied upon the at least part of the upper surface of the panel is in particular applied in an uncured condition. At least part of the at least one primary coating can be applied in a liquid, semi-viscous or viscous state. The at least one coating layer formed can be an uncured or a partially cured wear layer or lacquer. The at least one secondary coating as applied upon the at least one primary coating layer is preferably applied in an uncured condition. At least part of the at least one secondary coating can be applied onto the primary coating layer in a liquid, semi-viscous or viscous state. It may be advantageous if the at least one primary and / or at least one secondary coating is applied in a liquid or semi-viscous state to allow full coverage of the surface of the primed substrate. In one embodiment, it may be particularly advantageous if the at least one secondary coating is applied in a semi-viscous state, preventing said coating from filling the embossing or texture applied in a previous step.

[0032] As indicated above, the primer layer, the primary coating layer and / or the secondary coating layer may form a finishing layer. The finishing layer preferably has a Shore D hardness of at least 70, preferably at least 75 in particular after 10 seconds, more in particular when tested according to ISO 48-4. In a preferred embodiment, the Shore D hardness is at most 95, preferably at most 90, more preferably at most 85, as excessively high hardness values correlates with brittle behavior and microcrack initiation at sharp texture peaks, whereas the stated upper threshold maintains a balance between scratch / abrasion resistance and impact tolerance, thereby improving long-term durability of the surface structure. As an alternative method, the hardness of the finishing layer may be measured and expressed by ASTM D3363 and or ISO 1518. In a preferred embodiment, thehardness of the finishing layer is at least 2H when measured according to ASTM D3363 and / or at least 2200g when measured according to ISO 1518, both of which are indicators of a high surface hardness and, in some embodiments, correlate with and / or correspond to a Shore D hardness of at least 85 for the finishing layer.

[0033] Curing of the at least one primary coating layer is preferably done via radiation and wherein the at least one texturing medium is at least partially permeable for said radiation. At least part of the at least one texturing medium is preferably permeable to UV light. Preferably, at least part of the texturing medium has an UV-A transparency, or UV-A permeability, of at least 60%. It is for example conceivable that at least part of the texturing medium has a UV-A transparency in the range of 60% to 100%, in particular in the range of 70% to 90%. It is conceived that the UV-A transparency is at most 95%, preferably at most 90%, because excessive UV transmission through certain polymer films can increase heat build-up and / or accelerate tool aging, whereas insufficient UV-A transparency below about 60% may lead to undercure, residual tack and reduced abrasion resistance. Accordingly, a UV-A transparency window of 70% to 90% enables efficient through-cure while maintaining tool robustness and stable process conditions, which contributes to consistent texture replication. The finishing layer preferably has a transparency value of at least 90% and at most 99%. It is conceivable that at this transparency range, print clarity is preserved while still enabling functional surface performance. In this way, the use of the finishing layer will not negatively affect the appearance of the decorative layer.

[0034] In a further embodiment, the finishing layer and / or at least one primer layer and / or at least one coating layer comprises at least one UV additive configured to protect the decorative pattern from UV-induced fading, wherein the UV additive comprises UV-filtering and / or UV-scattering nanoparticles selected from TiO2, ZrO2and / or SiO2, preferably having an average particle size below 0.5 pm, more preferably below 0.2 pm, such that the finishing layer provides a UV cut-off function while maintaining transparency (e.g., transparency value at least 90%) and low haze. In this embodiment, the UV cut-off function that is typically provided by a conventional thermoplastic wear layer may be replaced by the UV additive in the primer / coating system, thereby enabling a digital-print product without requiring a separate wear layer while still preserving long-term decor appearance.The aesthetic appearance of the panel could for example also be enhanced by the finishing layer, and in particular the primer layer and / or lacquer layer, comprising at least one matting agent, such as a matting powder. It is also conceivable that the finishing layer is subjected to an excimer finishing step for obtaining higher density at the top surface of the coating finishing layer, for example within 1 to 5 pm from the top surface. It is conceived that densification within 1 to 5 pm provides a hard, wear-resistant and scratch-resistant upper region while leaving underlaying layers more compliant, thereby reducing crack initiation at sharp peaks and improving long-term texture retention under abrasion. In a preferred embodiment, the densified surface region is at most 10 pm thick. This is beneficial as beyond this thickness or deeper densification is conceived to increase brittleness and reduce impact tolerance without proportionate gains in abrasion resistance. At least one finishing layer is preferably substantially equal in thickness over its volume. The finishing layer preferably has a thickness in the range of 0.01 mm to 0.30 mm, preferably in the range of 50 pm to 200 pm. It is conceivable that a thickness of about 0.01mm, preferably about 50 pm, provides a sufficient material volume to form and retain the desired surface structure and to embed functional additives such as abrasive particles without premature breakthrough, whereas a thickness above 0.30mm may increase residual stress and risk of dimensional instability and / or may increase the tendency of coatings to level and partially fill texture valleys. Accordingly, it is preferred that the thickness of the finishing layer is at most 200 pm to balance texture definition and durability with dimensional stability and process robustness.

[0035] In a further embodiment, at least part of the upper surface of the panel comprises at least one relief structure comprising (i) at least one superficially textured region having at least one surface impression with a maximum depth with respect to an upper surface plane of 50 pm, and (ii) at least one deeply textured region comprising a plurality of surface impressions having an average depth with respect to the upper surface plane in the range of 50 to 250 pm. Preferably, the superficially textured region and the deeply textured region each exhibit an average gloss level between 2-6 Gu when measured at a 60 degree angle. This combination results in achieving a low-gloss appearance across both regions while maintaining distinct tactile depth. Preferably, the deeply textured region exhibits an average gloss level which is lower than the superficially textured region, indicativeof a lower gloss level within the deep texture. In this embodiment, the relief structure may be formed by a pressing structure, embossing roller, press plate, and / or a foil transfer layer, and the pressing structure may comprise a macro texture and a micro texture, where the micro texture is configured to impart a controlled microroughness that contributes to the low gloss appearance.

[0036] At least part of the at least one primary coating layer is preferably at least partially cured during and / or after step c). Curing of the at least one secondary coating layer may also be done via radiation and the at least one secondary texturing medium should be at least partially permeable for said radiation. Hence, possibly the at least one primary coating and / or secondary coating is UV curable and at least one curing step of said primary coating layer and / or secondary coating layer involves the application of ultraviolet light.

[0037] In a further embodiment, at least part of the primary coating layer and / or the resin / primer layer is brought into a semi-cured or pre-gelled state prior to mechanical embossing, wherein the pre-gel step is performed using a narrow UV wavelength band, preferably 390-450 nm, more preferably 390-400 nm and most preferably about 395 nm, thereby promoting through-cure while reducing undesired surface crust formation. This is advantageous because a surface crust on a semicured layer is conceived to form cracks / white blemishes when a mechanical embossing is applied. In such embodiment, the texturing medium may comprise a texture roller, press plate, embossing roller and / or a foil transfer layer, and at least part of the texture depth may be in the range of 0.05 to 0.4 mm, preferably 0.1 to 0.3 mm, while still enabling controlled curing and high-fidelity texture transfer.

[0038] At least one coating may be an excimer coating. It is conceivable that both the primary coating and the secondary coating are excimer coatings. However, it is most advantageous if the at least one secondary coating is an excimer coating. It is particularly advantageous if the at least one primary coating is an at least partially flexible coating. The combination of at least one at least partially flexible primary coating and at least one excimer cured secondary coating has a synergistic effect which is particularly suited for use on a panel according to the present invention, allowing for a particularly rigid, tough and rough top surface while allowing for a deep embossing to be applied. Excimer coatings benefit of good optical andphysical properties. The excimer coating may be rapidly cured using ultraviolet (UV) light, potentially enabling faster production times and reduced energy consumption compared to traditional curing methods. This UV curing process may result in a fully polymerized coating with enhanced cross-linking, potentially improving the coating's resistance to scratches, abrasion, and chemical exposure while also enhancing aesthetic qualities such as gloss and color depth. In some cases, the excimer coating and its UV curing process may contribute to the panel's overall durability and longevity by providing an additional protective barrier against environmental factors. The primer layer is preferably relatively soft and / or flexible after curing by virtue of its high viscosity while having a relatively high Shore D after curing. This means in practice that the primer layer has a soft touch, soft skin and / or silk feel finish, whereas when combining the transparent primer layer according to the present invention with at least one coating, all of the advantages of the coating layer are achieved but then with a coarse, rough texture which is desired for example floor panels. Soft skin effects are not suitable for use in a floor panel as it would not meet the requirements of EN 14041 on safety and slip resistance. Another unexpected or added effect of the use of at least one excimer curing is the heat generated during curing of the secondary coating layer, which may cure the resin of the primer layer faster. One might say that a high energy radiation step applied to the at least one secondary coating layer’s curing process thus results in a faster curing of the primer layer, a higher crosslinking rate and a high Shore D hardness. In one preferred embodiment, the Shore D hardness of the finishing layer after curing can thereby achieve a Shore D of at least 80, preferably at least 82, most preferably at least 85 after 10s of compression, at least 2H when measured to ASTM D3363, and / or at least 2200g when measured to ISO 1518 Another additional or alternative curing method is electron beam curing which will also lead to immediate curing of the primer layer and will have a reduced heat compared to excimer radiation. Hence at least one curing step applied in the present invention may be UV curing and / or electron beam curing.

[0039] The at least one primary coating is preferably at least partially flexible prior to curing, and preferably also at least partially flexible after curing when tested according to ISO 48-4. It is for example possible that during testing the Shore D needle will penetrate the secondary coating up to a depth that is equal to the thickness of the primary coating, showing for example a changing hardness from1s-5s-10s-15s. Due to the limited thickness of the primary coating, a detectable reduction of shore D would preferably be less than 10%, preferably less than 5% over a Delta of 10 seconds, which would reflect an equivalent Shore D of the at least one primer layer and at least one secondary coating layer, while allowing a lower Shore D of the at least one primary coating layer. As such the panel can exhibit a scratch resistance of at least 2500g when tested according to ISO 1518.

[0040] It is possible that the at least one secondary coating differs from the at least one primary coating. The at least one secondary coating may have a different composition from the at least one primary coating. Preferably, the at least one primary coating layer has a lower Shore D hardness than the at least one secondary coating layer, in particular in cured condition. The use of a secondary coating that differs from the primary coating may offer several advantages in the production of decorative panels. By employing coatings with distinct compositions, the properties of each layer can be tailored to meet specific performance requirements. For instance, the primary coating may be formulated to provide excellent adhesion to the substrate and flexibility, while the secondary coating may be designed to offer superior scratch and wear resistance. In some cases, the primary coating may have a lower Shore D hardness than the secondary coating in the cured condition, potentially allowing for a balance between impact resistance and surface durability. This hardness differential may contribute to improved overall panel performance, as the softer primary layer may absorb impacts while the harder secondary layer resists abrasion. Alternatives to this approach may include using a single coating formulation with gradient curing, applying multiple layers of the same coating with different additives, or utilizing a multi-functional coating that changes properties during the curing process. The at least one primary coating and / or the at least one secondary coating may comprise UV-curable acrylic, polyurethane, and / or polyester resins. The at least one texturing medium and / or the at least one secondary texturing medium may have a wavelength cut-off in the range of 150 to 400 nm, preferably in the range of 240 to 380 nm and more preferably in the range of 280 to 315 nm.

[0041] At least one texturing medium may comprise at least one negative surface texture and / or at least one secondary texturing medium may comprise at least one secondary negative surface texture. The texturing medium comprising at least onenegative surface texture and / or the secondary texturing medium comprising at least one secondary negative surface texture may offer precise control over the final surface appearance of the decorative panel. This approach may allow for the creation of complex, multi-level textures that closely mimic natural materials or create unique designs. The use of negative surface textures may enable the production of panels with consistent and repeatable surface patterns. It is possible that at least one texturing medium and / or at least one secondary texturing medium comprises an embossing roller, transfer film and / or a textured foil. In some cases, employing an embossing roller as a texturing medium may facilitate high-speed, continuous production processes, potentially increasing manufacturing efficiency. Alternatively, a textured foil or transfer film may provide flexibility in design changes and potentially reduce tooling costs. The transfer film may allow for the application of intricate textures that might be challenging to achieve with mechanical embossing alone. Mechanical texturing mediums, such as embossing rollers or plates, may offer durability and longevity in high-volume production environments. The choice between these texturing methods may depend on factors such as production volume, desired texture complexity, material properties, and manufacturing capabilities. In some instances, a combination of these texturing approaches may be employed to achieve optimal results.

[0042] It is also conceivable that the at least one texturing medium comprises at least one mask and / or that the at least one secondary texturing medium comprises at least one secondary mask. The (primary) mask and / or secondary mask may comprise a mask pattern. Such mask pattern may reflect a surface texture. At least part of the mask is typically not permeable for the curing medium, preferably UV light, such that the primary and / or secondary coating below the mask will not be cured during the curing step. After part of the coating layer which is exposed to the curing medium is cured, the texturing medium can be removed, and the remaining uncured coating layer can be removed too. Typically, at least part of the mask is permeable for the curing medium such that part of the coating layer can be cured. It is conceivable that only a fraction of the applied UV light will permeate through at least part of the mask, such that different degrees of curing are obtained. This may result in the provision of a surface structure. The method according to the invention may comprise the step of removing part of the uncured primary coating layer afterthe curing step and / or removing part of the uncured secondary coating layer after the secondary curing step.

[0043] It is for example possible that the primary coating layer, the secondary coating layer and / or the finishing layer has a peel strength value of at least 1 N / mm, preferably within the range of 2 N / mm to 5 N / m. This will enable adequate removal of the transfer film. After removal of the transfer film, the upper surface of the panel is ready for (industrial) use. However, it is still possible that an additional surface treatment is applied to the panel and in particular to the finishing layer. At least one texturing medium can be applied in combination with or forms part of at least one embossing mould. The embossing mould may be designed as a die and / or made of a material selected from metal, plastic, wood, rubber, stone, and textile.

[0044] It is conceivable that at least one secondary texturing medium is applied on top of the at least one secondary coating layer. After transferring of the texture and at least partially curing of the finishing layer, the at least one secondary texturing medium can be removed. Possibly, the method comprises the step of removing the secondary texturing medium from the finishing layer. It is preferred that the surface energy of the at least one secondary texturing medium is lower than the surface tension of the at least one secondary coating layer. This means that the surface energy of the at least one secondary texturing medium is lower than the surface tension of the at least one uncured secondary coating layer. This will enable that the secondary texturing medium can be removed without affecting the structure of the finishing later. The surface tension of the finishing layer can for example be below 38 dynes per centimetre.

[0045] The upper surface of the substrate is preferably substantially flat. It is for example conceivable that the upper surface of the substrate is free of any texture. The method further may comprise the step of aligning the at least one surface texture of the at least one texturing medium with at least part of the decorative pattern of the upper surface of the at least one substrate. The at least one decorative pattern of the at least one substrate may comprise for example at least one positioning marker and the texturing medium may align with at least one positioning marker through a positioning step prior to and / or during step d). It is also conceivable that the second texturing medium is aligned with at least one positioning marker througha positioning step prior to and / or during step h). Aligning the surface texture of the texturing medium with the decorative pattern of the substrate may enhance the realism and aesthetic appeal of the final product. This alignment process may create a synchronized texture that corresponds to visual elements of the decorative pattern, potentially resulting in a more authentic representation of natural materials or intricate designs. The use of positioning markers on the substrate may facilitate precise alignment, potentially improving consistency across production runs and reducing waste due to misalignment. These markers may be detected by optical sensors or other positioning systems, allowing for automated or semi-automated alignment processes. Aligning both the primary and secondary texturing mediums with positioning markers may enable the creation of complex, multi-layered textures that are accurately registered with the underlying decorative pattern. This approach may offer benefits such as enhanced depth perception, improved tactile qualities, and the ability to create more sophisticated designs.

[0046] The at least one texturing medium could be applied in combination with a press. The at least one texturing medium is preferably a substantially flexible texturing medium. It is possible that the applied surface texture extends into the at least one primary coating layer. This means that a relatively deep surface roughness can be obtained. The method according to the invention can provide for a surface roughness (Ra) of the at least one finishing layer of at least 4 pm, preferably at least 5 pm or 6 pm. The average maximum height (Rz) of at least part of the texture of the at least one finishing layer can be at least 15 pm, preferably at least 20 pm or 22.5 pm. The method according to the invention enables the provision of structural depths of the texture in the finishing later with a single application which results in improvement of the visual and haptic appeal of the panel.

[0047] Possibly, the (transparent) primer applied at step b) is at a temperature of at least 60 degrees Celsius, preferably at least 80 degrees Celsius. It is also conceivable that the primer is applied at a temperature in the range of 80-120 degrees Celsius. The (transparent) primer may have a viscosity of at least 5,000 mPa-s, preferably at least 6,000 mPa-s, conceivably up to 8,000 or at most 10,000 at time of application. It is conceivable that the primer is at least partially thixotropic.

[0048] Preferably, said primer layer has thixotropic properties to allow a single layer application of at least 50 g / m2, more preferably at least 80 g / m2. Applying thetransparent primer at elevated temperatures of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and up to 120 degrees Celsius, may offer several advantages in the production of decorative panels. This temperature range, preferably combined with the high viscosity of at least 5,000 mPa-s, preferably at least 6,000 mPa-s and / or the primer layer being at least partially thixotropic, may allow for a single and immediate buildup of up to 140 g / m2 without the need for multiple layer applications. This approach may result in improved production efficiency compared to more liquid UV coating layers used in prior art methods. The high viscosity and / or thixotropic property or thixotropic character of the primer may also enable the application of pronounced textures, as the primer layer may maintain mechanically applied deformation for an extended period. The method may accommodate various thickness ranges, potentially corresponding to different abrasion class (AC) ratings, such as 90-140 g / m2 for AC5 and 70-100 g / m2 for AC4. The primer layer thickness may range from 0.06 to 0.14 mm. At least one primer may be applied in a quantity of at least 50g / m2, preferably at least 60g / m2, more preferably at least 70g / m2. In a preferred embodiment, the primer is applied in a quantity of at most 140 g / m2, more preferably at most 120 g / m2. In another preferred embodiment, at least one primer is applied in a quantity in a range of 80-100 g / m2. It is conceived that a threshold of at most 140g / m2, preferably at most 120 g / m2 prevents excessive primer build that is conceived to increase thermal mass and cure time and consequently reduces risk of print disturbance or entrapped volatiles. It is also conceived that a threshold of at least 50g / m2, more preferably at least 60g / m2 ensures that low primer build is prevented thereby also ensuring that texture is formed and extended into the primer thereby achieving dimensional stability. The primer is preferably applied at an elevated temperature, for example at least 80C, at least 10 degrees above environmental temperature and / or a temperature above 25 degrees Celsius.

[0049] At least one primary coating can be applied in a quantity of 5-20g / m2, preferably 8-15 g / m2 in particular at room temperature, preferably 20-40 degrees Celsius or most preferably around 20-30 degrees Celsius. At least one secondary coating may be applied in a quantity of 5-20g / m2, preferably 8-15 g / m2 in particular at room temperature, preferably 20-40 degrees Celsius or most preferably around 20-30 degrees Celsius.Possibly, the temperature of the at least one primary coating applied is at ambient conditions, in particular in a range from 15 degrees Celsius to 50 degrees Celsius. It is for example possible that the temperature of at least one primary coating applied at is substantially 20-40 degrees Celsius. Possibly, the at least one primary coating has a viscosity of at most 10,000 mPa-s, preferably at most 2,000 mPa-s to 5,000 mPa-s in particular at time of application. Additionally or alternatively, the at least one primary coating is thixotropic at time of application. The mass or weight of the composition of the at least one primary coating applied to an area of the at least part of the upper surface of the panel is preferably in a range from 2 to 30 g / m2. It is for example possible that the mass of the primary coating layer is in a range from 5 to 20 g / m2, in particular 7-15 g / m2. The at least one finishing layer may be cured at an energy level ranging from 100-200 mJ / cm2and / or at a wavelength of 150-400nm. The at least one finishing layer could also be subjected an energy levels of up to 700-900 mJ / cm2. The curing of the finishing layer could also be performed at a wavelength of below 220nm.

[0050] The primer is preferably applied in a larger quantity compared to the primary coating layer and / or in a larger quantity compared to the second coating layer, preferably in a ratio of at least 5:1 , preferably at least 7.5:1 , most preferably at least 10:1. In a preferred embodiment, the ratio is at most 20:1, more preferably at most 15:1. It is conceived that at a ratio of at most 20:1 , an optimal thickness of the base is achieved thereby promoting replication of fine surface details. It is conceived that at a ratio of at least 5:1 and at most 20:1, preferably at least 7.5:1 and at most 15:1, a sufficient dimensional stability while maintaining high-fidelity texture transfer and durable top surface is achieved. This exhibits a good dimensional stability, preventing shrinking and expansion of the primer layer, and preventing resulting deformation of the panel. Upon heating and subsequent cooling, the primer layer according to the present invention maintains its volumetric density and does not exhibit a reduction in volume, a polymerization shrinkage or volume shrinkage, unlike an 80-100 gram / m2 UV-curable coating according to the prior art that may shrink and cause warping due to the polymerization reaction and creation of a more compact molecular structure. With the combination of layers applied in the present invention, such issues are avoided, making it one of the primary benefits of using the primer in combination with the primary coating layer and / or the secondarycoating layer according to the present invention. Typically, the primer layer is thicker than the primary coating layer and / or the secondary coating layer.

[0051] Preferably, the at least one primary coating layer and / or the at least one secondary coating layer comprises at least one photo-initiator. The photo-initiator is typically configured to enable UV curing and / or crosslinking. Said photo-initiator can be any chemical compound that decomposes into free radicals when exposed to UV to initiate crosslinking of coatings directly on a surface. Said photo-initiator can be any radical photo-initiator or cationic photo-initiator. It is conceivable that the at least one photo-initiator can be a compound selected from the group comprising of: acrylate- or styrene-based formulations, methyl-2-benzoylbenzoate, 2-hydroxy-2-methyl-1-phenyl-1 propanone, benzyl dimethyl ketal, 1-hydroxy-cyclohexylphenyl-ketone, or methyl benzoyl formate, or other photo-initiator, or any combination thereof. It is possible that the photo-initiator can comprise of about 2 wt% to about 10 wt %, preferably 2 wt% to about 5 wt %, more preferably 3 wt % based on total weight of the coating formulation. In case a crosslinkable oligomer is applied, the at least one crosslinkable oligomer is preferably an acrylic oligomer or a polyurethane oligomer. The secondary coating layer can be a polyurethane acrylic coating layer. The secondary coating layer layer may also comprise a material selected from the group consisting of thermoplastic material, thermosetting material, polyurethane coating, acrylic coating, epoxy polyol coating, polypropylene (PP), polycarbonate (PC), abrasion resistant material, slip resistant material, water resistant material, chemical resistant material, temperature resistant material, or a combination thereof.

[0052] The secondary coating layer may for example be an acrylic lacquer. The at least one secondary coating layer may optionally comprise at least one crosslinkable prepolymer and / or at least one photo-initiator and / or at least one additive. A non-limitative example of a prepolymer which can be used is an acrylic prepolymer or a polyurethane prepolymer. Alternatively, at least one prepolymer can be an epoxy polyol coating. In another preferred embodiment, the secondary coating layer comprises at least one crosslinkable oligomer, at least one monomer and / or at least one photo-initiator. The crosslinkable oligomer can for example be an acrylic oligomer or a polyurethane oligomer. Optionally, the secondary coating layer maycomprise at least one additive, for example in order to further improve scratch, abrasion, slip resistance, UV resistance and / or other factors.

[0053] The secondary coating layer may comprise polyurethane such as polyurethane obtained from a chemical reaction of at least one isocyanate and water. It is also conceivable that the polyurethane of at least one secondary coating is obtained from the polycondensation of at least one non-isocyanate and at least one polyol, or alternatively through polyaddition and / or polycondensation of at least one functional polyisocyanate and at least one polyol and / or at least one polyamine. This flexibility may allow for tailored performance characteristics and potentially reduce environmental concerns associated with isocyanates. The resulting material may comprise at least 99% of a crosslinked polyurethane and / or acrylic after reacting, potentially offering excellent durability and chemical resistance. The secondary coating may also comprise polyvinylchloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), polyethylene (PE), polyurethane (PU), acrylonitrile butadiene styrene (ABS) and / or co-polyester (CPE).

[0054] At least one primer may comprise polyurethane. This may be polyurethane obtained from a chemical reaction of at least one isocyanate and water. It is also conceivable that the polyurethane of at least one primer is obtained from the polycondensation of at least one non-isocyanate and at least one polyol, or alternatively through polyaddition and / or polycondensation of at least one functional polyisocyanate and at least one polyol and / or at least one polyamine. At least one primer may be a reactive polyurethane hotmelt. It is for example possible the at least one reactive polyurethane hotmelt comprises a polyol and an isocyanate. The polyol can be a compound containing multiple hydroxyl groups and the isocyanate can be a compound containing one or more isocyanate groups. When these components are mixed together, a chemical reaction occurs, leading to the formation of a polyurethane polymer. A non-limiting example of a reactive polyurethane hotmelt is a two-component system with aromatic polyisocyanates as hardener which is formulated with a solids content of 25-40% in solvents such as ketones, esters, and aromatic compounds. Non-limiting examples of polyols which can be used for the present invention are polyether polyols, polyethylene glycol (PEG), polypropylene glycol (PPG), polyester polyols (dicarboxylic acids and diols)and / or polycarbonate polyols. Non-limiting examples of (poly)isocyanates which can be used for the preset invention are toluene diisocyanates (TDI), methylene diphenyl diisocyanate (MDI) and / or hexamethylene diisocyanate (HDI). For the present invention, the at least one reactive hotmelt may comprise at least one functional polyisocyanate and / or at least one polyol and / or at least one polyamine. It is also possible that the at least one reactive hotmelt is obtained from the polycondensation of functional polyisocyanate and / or at least one polyol and / or at least one polyamine. In another possible embodiment, the at least one reactive hotmelt can be obtained from the polycondensation of at least one non-isocyanate and at least one polyol.

[0055] At least one secondary coating may comprise epoxy acrylate, polyurethane, 1,6-Hexanediol diacrylate, dipropylene glycol diacrylate, polyester acrylate resin, polyester polyol resin, polyester resin comprising acrylate and polyol functions, polyester acrylate resin with grafted hydroxyl groups, or combinations thereof.

[0056] In a possible embodiment, the panel may comprise multiple primary coating layers and / or multiple secondary coating layers. It is conceivable that multiple coating layers are applied prior to the texturing medium being applied. In a possible embodiment, the panel may comprise one primer layer and one primary coating layer and / or one primer layer and one secondary coating layer.

[0057] Preferably, the panel comprises a core layer and at least one top layer. The at least one top layer can be a decorative top layer which optionally comprises a decorative print. It is also possible that the panel comprises a decorative print. The method may include the step of aligning the at least one texturing medium with respect to the decorative print. In this way, embossing in register of the texture over the decorative print can be obtained. It is possible that the texture of the at least one texturing medium corresponds to the decorative print of the panel. Hence, it is possible that the texture of the texturing medium follows the characteristics of the decorative pattern. This is for example possible for natural patterns, such as wood structures. The method may further comprise the step of applying at least one decorative print upon at least part of the upper surface of the decorative panel prior to step b). It is possible that the decorative print is directed provided upon the upper surface of the core layer. It is also possible that the decorative print is applied uponthe core layer via a top layer. Possibly, at least one primer is applied prior to application of the decorative print. This may enhance the quality and durability of the print. It is possible that the at least one decorative print is a digital print. Hence it is possible that the decorative print is applied via digital printing. It is possible that the decorative print is applied via transfer printing. It is possible that the application of the decorative top layer and / or the decorative print is applied in the same dimensional plane as the application of the texture, for example a substantially horizontal plane. It this way it can be prevented that stretching negatively affects the aligning. It is possible that aligning markers are applied on the side of the panel for identification and / or aligning purposes. In case a continuous production line is applied, the speed of the device controlling the transfer or texture film can be aligned with the speed of the conveyor transporting the panel. Sensors, such as infrared and / or image sensors, could sense the aligning markers and / or edge of a board or panel, wherein a control unit can determine the desired settings of the systems. The thickness of the top layer is preferably in the range of 0.05 mm and 0.10 mm, for example substantially 0.07 mm. It possible that the decorative top layer is a paper layer laminated onto the core layer.

[0058] In a further embodiment, the decorative layer comprises a cellulose-based carrier layer which is printed with a decorative pattern by digital printing, inkjet printing, rotogravure, or transfer printing, wherein the printed paper is subsequently impregnated and / or infiltrated by at least one thermosetting resin supplied from a powder layer, a liquid layer, a liquid dispersion and / or a resin-impregnated paper provided under and / or over the printed paper, such that the resulting resin-impregnated decorative layer forms a resin-rich surface region. In this embodiment, the resin-impregnated decorative layer can function as a wear-providing layer and can replace a conventional AlOx-containing overlay layer, while remaining compatible with the method of the present invention by applying the primer layer and / or the primary coating layer directly onto said resin-rich region. The resin-impregnated decorative layer may further be combined with the texturing medium and curing steps of the present invention to provide a texture in register with the printed pattern (El R).

[0059] The present invention basically relates to a method for providing panels with a digital print and corresponding embossing wherein the method provides forenhancing both the embossing procedure and the print quality. The method is preferably employed on panels that feature a decorative design, such as one imitating wood grain, ensuring precise alignment during embossing. However, the method described in this invention can also be utilized to achieve embossing that does not align with the existing pattern or even to emboss a panel lacking a specific decorative design.

[0060] In one embodiment, at least one primer may comprise at least one texture on at least one side edge which forms a groove or recess on said at least one edge, preferably at two non-opposing edges, such that the visual effect of a grout is obtained when panels are interconnected or abutted. In a further embodiment, at least one groove or recess may further be applied at a distance of at least one edge, preferably equidistant from two opposing side edges. In this embodiment, the groove or recess has a depth which extends through the primer. The at least one groove or recess reaches substantially the design layer. Preferably, at least one groove or recess is formed in the primer and does not extend through the design layer. The groove or recess may be formed by placing a texturing or embossing medium onto the primer prior to curing of the primer layer. The primer, including said groove or recess may then be covered with at least one primary and / or secondary coating layer. The at least one groove may be formed by selectively applying at least one mask or texturing medium prior to the curing of said primer layer.

[0061] In one embodiment, the at least one primer layer may be partially flexible allowing for its at least partial deformation under heat and / or pressure. The at least one primer layer at at least one side edge of a panel may be subject to a temperature of 90-120C and a pressure of at least 500kPa, preferably at least 1 MPa for at least one time period, allowing for mechanical deformation of the underlying core and / or primer layer without cracking or whitening.

[0062] In other embodiments, the surface roughness (Ra) of the at least one finishing layer is preferably below or equal to 50 pm, preferably below or equal to 25 pm, more preferably below or equal to 15 pm. It is also possible that the surface roughness (Ra) of the at least one finishing layer is in the range of 5 to 50 pm, preferably in the range of 10 to 25 pm, more preferably in the range of 12.5 to 20 pm. At leastpart of the finishing layer may comprise a plurality of micro-undulations. An adequate surface roughness of the upper surface of the panel can positively contribute to the bonding between the primer layer and the panel. It is in particular preferred that the panel has a (surface) roughness (Ra) of at least 0.5 pm. More preferably, the roughness of the panel is at least 1 pm. Hence, the upper surface of the panel may have a roughness of at least 0.5 pm, preferably at least 1 pm. In a preferred embodiment, the roughness of the upper surface of the panel prior to coating is at most 5 pm, more preferably at most 3 pm. These characteristic enables proper bonding between the upper surface of the panel and the coating layer(s). It is also possible that the upper surface of the panel is subjected to a surface treatment prior to application of the secondary coating layer. The upper surface of the panel optionally comprises a macrotexture with depths and / or heights imitating a real stone or wood surface, preferably applied by mechanical or chemical means. It is preferred that the maximum texture depth is at most 0.6 mm, for example in the range of 0.3 to 0.5 mm, possibly with a variance of maximum 0.1 mm.

[0063] The average maximum height (Rz) of at least part of the texture of the at least one finishing layer is preferably below or equal to 50 pm, preferably below or equal to 40 pm, more preferably below or equal to 30 pm. The maximum peak to valley height van for example be at most 20 pm or 25 pm. The surface roughness and / or micro-undulations of the panel can positively contribute to the slip resistance of the finishing layer, and thus for the panel as such.

[0064] The panel and / or core layer may for example have a thickness of at least 4 mm. It is for example possible that the thickness of the core layer is between 3 and 9 mm, preferably between 4 mm and 5.5 mm or between 5.5 mm and 7 mm. The panel, and in particular the core layer, may optionally comprise complementary coupling parts. The core could for example comprise at least one pair of opposite side edges which are provided with complementary coupling parts. The complementary coupling parts, if applied, are typically configured for interconnecting adjacent panels. Typically, at least one pair of opposite side edges of the core layer is provided with complementary coupling parts. For example, the core layer comprises at least one pair of complementary coupling parts on at least two of its opposite side edges. Said coupling parts may for example be interlocking couplingparts configured for mutual coupling of adjacent panels on multiple directions.

[0065] Preferably, said interlocking coupling parts provide locking in both horizontal and vertical directions. Any suitable interlocking coupling parts as known in the art could be applied. For example, said interlocking coupling parts may be in the form of complementary tongue and groove, male and female receiving parts, a projecting strip and a recess configured to receive said strip or any other suitable form. It is conceivable the complementary coupling parts require a downward scissoring motion when engaging, or are locked together by means of a horizontal movement. It is further conceivable that the interconnecting coupling mechanism comprise a tongue and a groove wherein the tongue is provided on one side edge of one pair of opposite side edges, and the groove is provided on the other side edge, or an adjacent side relative to that of the tongue, of the same pair of opposite side edges. Such a design of coupling mechanism is well-known in the art and has proven highly suitable for panels for floor coverings such as a floating floor. In a further embodiment it is possible that the interconnecting coupling mechanism have an interlocking feature which prevents interconnected panels from any free movement (play). Such an interlocking feature may be a projection and a respective recess provided on the respective opposite side edges by which neighbouring panels interlock with each other. It is conceivable for provisions of reinforcement in the interlocking coupling parts to improve strength and prevent breakage thereof during installation of the panels. For example, the complementary or interlocking coupling parts may be reinforced with materials such as but not limited to fiberglass mesh, reinforcing sheets, carbon fibers, carbon nanotubes, ceramics, glass, arrays of metallic or non-metallic rods, or polymer compounds integrally formed in the core layer. It is also conceivable that a strengthening coat layer of micro or nanotechnology is added on the surface of the interlocking coupling parts. The panel according to the present invention and / or the panel obtained via the method according to the present invention is suitable for use in flooring, wall or ceiling coverings preferably featuring a locking mechanism. As such a 'floating' covering can be assembled by interconnecting the individual panels with each other at all four sides, without the need for adhesives. The panel according to the present invention may also be suitable for use in worktops, countertops, shower bases, and / or washbasins.The panel may comprise at least one further layer, such as but not limited to a backing layer. The method according to the present invention may also include the step of providing and / or attaching at least one backing layer to the bottom surface of the core layer. In case a backing layer is applied, the backing layer can be adhered on the bottom surface of the panel, and in particular of the core layer via an adhesive. The backing layer is preferably made of a polymer material, for example but not limited to polyurethane. The backing layer may also be a sound absorbing layer. Such sound absorbing backing layer may further contribute to the good acoustic properties of the panel. Such backing layer may also be referred to as an acoustic layer. The backing layer may be composed of a foamed layer, preferably a low-density foamed layer, of ethylene-vinyl acetate (EVA), irradiation-crosslinked polyethylene (IXPE), expanded polypropylene (XPP) and / or expanded polystyrene (XPS). However, it is also conceivable that the backing layer comprises nonwoven fibers such as natural fibers like hemp or cork, and / or recycled / recyclable material such as PET. The backing layer, if applied, preferably has a density between 65 kg / m3 and 300 kg / m3, most preferably between 80kg / m3 and 150 kg / m3.

[0066] A few non-limiting examples of a panel manufactured by the method according to the invention are discussed hereinafter.

[0067] In a first example, a substrate with a digitally printed visual is provided. Then a primer layer is provided upon said digitally printed visual and subsequently a primary coating is applied upon the primer layer forming a primary coating layer. The primary coating layer has a first gloss level and is UV-curable. A first texturing medium is applied upon the primary coating layer, wherein the first texturing medium comprises at least one UV-mask. At least part of the primary coating layer is then at least partially cured by means of UV radiation, except in those locations where it was provided with said UV-mask. The at least one UV-mask is removed with at least part of the uncured UV-curable coating to form a plurality of cavities and / or a surface texture. At least one secondary coating can be applied upon the primary coating layer to form a secondary coating layer. The secondary coating layer will have a second gloss level. This method will results in that a panel is formed with a main surface with a second gloss level and a second surface defined by said plurality of cavities having a first gloss level.In a second example, a substrate with a digitally printed visual is provided. Then a primer layer is provided upon said digitally printed visual and subsequently a primary coating is applied upon the primer layer forming a primary coating layer. At least one uncured primary coating is applied upon at least part of the primed substrate, thereby forming at least one primary coating layer and a texturing medium comprising at least one surface texture onto at least part of the at least one primary coating layer. Subsequently, at least partially curing at least part of the at least one primary coating layer is performed such that a textured substrate is obtained. The texturing medium can be removed afterwards. Subsequently, at least one at least partially uncured secondary coating can be applied upon at least part of the textured substrate, thereby forming at least one secondary coating layer, and a secondary texturing medium comprising at least one secondary surface texture can be applied onto at least part of the at least one secondary coating layer. The next step is at least partially curing at least part of the at least one secondary coating layer and removing the at least one secondary texturing medium.

[0068] In a third example, the method steps of the second example are applied but at least part of the texture of the primary coating layer and / or at least part of the texture of the secondary coating layer matches the decorative design of the digitally printed visual. In this way, and embossing-in-register can be obtained.

[0069] The invention also relates to a panel, in particular a decorative panel, more in particular a floor panel, cladding panel, building panel, wall panel or ceiling panel, preferably obtained via the method according to the preset invention, the panel comprising:

[0070] - at least one substrate comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern, wherein the substrate is in particular a primed substrate;

[0071] - a finishing layer, comprising:

[0072] o at least one primary coating layer; and

[0073] o optionally at least one secondary coating layer;

[0074] wherein the finishing layer comprises a surface structure; and

[0075] wherein the surface roughness (Ra) of the at least one finishing layer is at least 4 pm, andwherein the at least finishing layer has a hardness of at least 75 Shore D in particular after 10 seconds in particular after 1 seconds more in particular when tested according to ISO 48-4.

[0076] The panel according to the present invention can be obtained via the method according to the present invention. The possible embodiments described for the method according to the invention also apply to the panel according to the invention, and vice versa.

[0077] The finishing layer forms at least partially a three-dimensional structure, in particular a dense three-dimensional structure. It can also be said that the finishing layer comprises a three-dimensional structure. In a preferred embodiment, the finishing layer is substantially transparent and / or translucent. The finishing layer preferably has a transparency value of at least 90%. The panel according to the invention benefits of a desired surface structure in combination with a good dimensional stability.

[0078] In a possible embodiment, the dimensional stability is achieved through a chemical reaction involving two components, preferably water-based, resulting in a (upper) coating layer of sufficient thickness that remains flat even after exposure to temperature fluctuations such as heat. For example, it can exhibit less than 0.1 mm of warping when tested according to ISO 23999 standards, highlighting its dimensional stability. For example, cupping of less than 1mm, preferably less than 0.5mm, more preferably 0.2mm, and most preferably less than 0.15mm. The dimensional stability of the panel can be demonstrated by its cupping and stability results in accordance with ISO 23999.

[0079] In a non-limiting example, the desired stability is achieved by applying at least 100 grams of acrylic or polyurethane coating on one surface which can still result for the panel to maintain its flatness and resist deformation, even after exposure to heat. This approach eliminates the need for a back-balancing coating. Where a panel according to the prior art comprising a coating with abrasion resistant particles, polyurethane acrylic UV curable lacquer layer which is applied in a quantity of 80 g / m2 results in cupping I warping according to ISO 23999 of 2-3 mm, the panel according to the present invention comprising a primer layer and at least oneprimary coating layer and / or at least one secondary coating layer according to the invention results in a cupping I warping according to ISO 23999 of 0.2-1 mm.

[0080] The abrasion resistance can be improved or at least remains comparable to the prior art, but the stability is significantly enhanced because the polyurethane used is not UV-curable but is instead formed through a chemical reaction. This method, achieved without photoinitiators, results in a higher cross-linking density and improved stability when exposed to heat. While UV-curable coatings, such as lacquer layers containing polyurethane, acrylics, and resins, are well known, the present invention improves upon these by utilizing a different type of polyurethane based on isocyanates and water. In the context of the present invention, the primary coating layer serves as a functional and stable base. In contrast, the secondary coating layer is typically not dimensionally stable and is preferably relatively thin, whereas the primary layer can be applied more thickly due to its stability.

[0081] The at least one primer layer may comprise a reactive polyurethane hotmelt. The at least one reactive hotmelt may be obtained from the polyaddition and / or polycondensation of at least one functional polyisocyanate and at least one polyol and / or at least one polyamine. In another possible embodiment, the at least one reactive hotmelt can be obtained from the polycondensation of at least one nonisocyanate and at least one polyol. The at least one reactive hotmelt could also be produced through a secondary polycondensation of at least one polyisocyanate, at least one polyol, at least one polyamine, and optionally at least one additive. Nonlimiting examples of additives for the secondary polycondensation are a chain extender, a crosslinker and / or a catalyst. At least one chain extender could react with isocyanate-terminated prepolymers to form urethane linkages, effectively extending the polymer chain. These likewise effectively improves the processability of the reactive hot melt. Chain extenders could for example comprise 1 ,4-Butanediol (BDO) in particular for flexibility and mechanical properties and / or 1 ,6-Hexanediol in particular for hydrolytic stability and impact resistance. Hence, the at least one reactive hotmelt may comprise at least one chain extender comprising 1 ,4-butanediol and / or 1 ,6-hexanediol. The polyisocyanate, in applied, can be selected from the group of toluene diisocyanates (TDI), methylene diphenyl diisocyanate (MDI), hexamethylene diisocyanate (HDI), or combinations thereof. The at least one polyol can be selected from the group of polyether polyols,polyethylene glycol (PEG), polypropylene glycol (PPG), polyester polyols, polycarbonate polyol, or combinations thereof.

[0082] In a possible embodiment, the at least one primer layer comprises at least 50 g / m2 of polyurethane resin, preferably at least 60 g / m2, most preferably at least 70 g / m2. Further the panel preferably has less than 0.1 mm cupping in particular when tested according to ISO 23999.

[0083] In a possible embodiment, the at least one secondary coating layer has a surface roughness Ra of 1 urn, and / or has a OOF of at least 0.35, preferably at least about 0.4 when tested to EN 14041. The finishing layer comprises at least partially a three-dimensional structure extending at least partially into said secondary coating layer and at least partially into said primary coating layer, wherein said three-dimensional structure has a depth ranging of at least 0.01mm, preferably at least 0.05mm, to at most 0.2mm. In a preferred embodiment, the three-dimensional structure is at least partially synchronized with said at least one decorative layer.

[0084] It is conceivable that the at least one finishing layer has a thickness of at least 0.05, preferably at least 0.1mm, and at most 0.2mm, preferably at most 0.15mm. The at least one finishing layer may have an abrasion resistance of at least abrasion class AC4. The finishing layer may have an abrasion resistance value of at least 4,000 cycles according to EN 13329. The abrasion resistance can for example be tested with a Taber abrasion test. The panel preferably has a micro scratch resistance of at least 2,000 g, in particular at last 2,200 g, more in particular at least 2,500 g, when tested to ISO 1518.

[0085] The surface structure of the panel is possibly formed of a surface texture and a mechanical embossing, wherein at least part of the mechanical embossing extends into at least part of at least one primer layer. The surface roughness (Ra) of the at least one finishing layer is below or equal to 50 pm, preferably below or equal to 25 pm, more preferably below or equal to 15 pm.

[0086] Typically, the panel comprises a core layer and at least one decorative top layer. In a possible embodiment, the at least one core layer comprises 10 -40 wt.% of at least one binder, 20 - 60 wt.% of at least one mineral filler, and optionally at least 4wt.%, of at least one plasticizer, in particular based on total weight of the at least one core layer. At least one binder can be selected from polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), chlorinated polyethylene (CPE), Polylactic Acid (PLA), Polyhydroxyalkanoates (PHA), Polybutylene Succinate (PBS), Polyhydroxyurethane (PHU), Cellulose Acetate (CA), Starch-based Bioplastics, Polyglycolic Acid (PGA), Polyhydroxyalkanoate-Co-Valerate (PHA-V), Polybutylene Adipate Terephthalate (PBAT), TPU, LDPE, LLDPE, HDPE, PS, HIPS, GPPS, PA, PETG, PPG, PC, ABS, PVDF, starch-based polymers, PHD, Bio-PE, LA, cellulose acetate, or any combination thereof. It is also possible that the core layer is at least partially foamed. The core layer can for example comprise foamed PET. Such material benefits of a low intrinsic viscosity. Foaming could be done via physical foaming and / or chemical foaming. Any of the core layer and top layers are described for the method according to the present invention could also be comprises in the panel according to the present invention. The same applies for the decorative top layer. Preferably, the decorative top layer comprises a digital print.

[0087] The panel in particular comprises a texture on the upper surface, wherein the texture comprises a plurality of cavities forming a first surface area and a second surface area, wherein the top surface area is the sum of the first surface area and the second surface area, wherein the first surface area and / or the second surface area have a gloss level deviation of less than 10Gu, more preferably less than 5Gu, most preferably less than 2Gu.

[0088] The panel according to the invention may comprise at least one finishing layer which comprises at least one abrasive additive selected from the group of aluminum oxide, corundum, quartz, silicon carbide, diamond particles, or any combination thereof. It is also conceivable that the at least one secondary coating layer is at least partially excimer cured. In another possible embodiment, the at least one finishing layer comprises at least 90%, preferably at least 95% of an acrylic resin and / or polyurethane.

[0089] In a non-limiting fourth example of an embodiment of a panel according to the invention, a decorative panel is produced using the method according to the present invention. A thermoplastic-mineral composite substrate of 4mm thickness is provided, featuring a digitally printed decorative pattern. A primer layer is applied ata temperature of 80C with a viscosity of 6,000 mPa-s, resulting in a coating weight of 80 g / m2and a thickness of 0.08mm. This primer layer is formulated with a moisture curable isocyanate-based polyurethane resinSubsequently, and prior to cooling of said primer, a primary coating layer of an at least partially flexible UV-curable acrylic is applied at a coating weight of 8 g / m2, cured partially to form a deformable partially jellified coating, followed by a texturing foil to create a defined surface texture extending into said primer layer. After partial curing through and removal of said texturing foil, a secondary coating layer of a hard excimer-cured polyurethane is applied at a coating weight of 12 g / m2, which is then cured via excimer radiation. The resulting panel exhibits a significant texture depth, with an average depth of 0.2mm, and a significant surface roughness with an average maximum height (Rz) of 20 pm, providing a notably realistic haptic appeal. The finishing layer thereby achieves a coefficient of friction (COF) of 0.42 as tested according to EN 14041, thereby ensuring good slip resistance. Furthermore, the panel demonstrates a scratch resistance of at least 2,500 g, according to ISO 1518 and / or a hardness of at least 2H when measured to ASTM D3363 providing a highly durable surface for high-traffic applications. The combination of the flexible primary coating and the hard excimer-cured secondary coating provides both deep embossing and a hard, wear-resistant surface. The combination of the moisture cured isocyanate-based polyurethane primer, the flexible primary coating and the hard excimer-cured secondary coating provides a panel which has a cupping rate of less than 0.1mm when tested to ISO 23999. The finishing layer, by virtue of the limited thickness of the primary coating layer, has a Shore D hardness of 80 after 10 seconds and a hardness change of less than 5 after 10 seconds exposure.

[0090] In a fifth non-limiting example of an embodiment of a panel and / or method according to the invention, a decorative panel is produced following a similar process. A substrate with a transfer printed decorative pattern is prepared and a primer layer composed of a reactive polyurethane hotmelt is applied at a temperature of 90 degrees Celsius with a viscosity of 8,000 mPa-s, resulting in a coating weight 120 g / m2and a thickness of 0,12mm. Preferably, said primer layer is at least partially thixotropic and / or has thixotropic properties to allow a single layer application of at least 50 g / m2, more preferably at least 80 g / m2. Following this, one primary and one secondary liquid coating layer of a low viscosity UV-curable polyester acrylate is applied at a total coating weight of 40 g / m2and textured usinga texturing medium that includes a removable mask for creating a specific texture after curing. After curing, a top coating layer, consisting of a hard-curing excimer coating is applied at a coating weight of 10 g / m2, followed by a full cure. The resulting panel achieves a surface roughness with an average maximum height (Rz) of 22.5 pm. The finishing layer exhibits a COF of 0.38, as tested to EN 14041 , demonstrating qualified slip resistance. Moreover, this embodiment shows a scratch resistance of 2,200 g according to ISO 1518 and an abrasion resistance of AC5 according to EN 13329, showing enhanced durability. In this design, an additional mechanical texturing medium may be provided onto the at least one primary coating layer to exten2-4ds into the primer layer to create a deep mechanical embossing. Although the primer layer has a Shore D hardness of at least 85, the application of two liquid coating layers with a relatively low Shore D hardness result in a final hardness of the finishing layer of at least 75 Shore D after 10 seconds, with a Delta of less than 8 after 10 seconds.

[0091] In a sixth non-limiting example of an embodiment of a panel and / or method according to the invention, a substrate is present with a decorative film and at least one primer layer comprising at least one textured region and at least one nontextured region. Said substrate is provided with a first coating layer having a first gloss level and a first viscosity, wherein said first coating layer preferably covers substantially the entire upper surface of the substrate. Subsequently a second coating layer having a second gloss level and a second viscosity is applied, wherein said second coating layer covers substantially said non-textured region. Said first gloss level preferably ranges from 2-4 Gu, said second gloss level preferably ranges from 3-6 Gu. Said first viscosity is preferably lower than said second viscosity, such that the first coating is provided on the surface area of the embossed and non-embossed surfaces, and the second coating is provided on the uppermost surface of the non-embossed surface.

[0092] In a further embodiment, a low-gloss embossed substrate is provided (e.g., SPG substrate having a macrotexture), and a first coating layer is applied to form a low-gloss bottom coating on the embossed substrate, wherein the bottom coating provides a first gloss level and preferably contributes to defining the perceived gloss of the embossed surface. Subsequently, a second coating layer having a slightly higher gloss level is applied as a thin conformal top coating, wherein thesecond coating layer is applied at a controlled viscosity and / or coat weight such that it does not substantially fill the valleys of the embossing and does not substantially cover or level the texture. Preferably, the first gloss level ranges from 2-4 Gu and the second gloss level ranges from 3-6 Gu, and the gloss difference between embossed and non-embossed regions is kept within about 1-4 Gu when measured at a 60° angle. This embodiment enables a low-gloss embossed panel while still providing a protective top surface on selected regions (e.g., nonembossed regions or peak regions), without sacrificing the tactile definition of the embossing.

[0093] The invention will be further elucidated by means of non-limiting exemplary embodiments illustrated in the following figures, in which:

[0094] - figure 1 shows a first possible embodiment of a panel according to the present invention, and

[0095] - figure 2 shows a second possible embodiment of a panel according to the present invention.

[0096] Within these figures, similar reference numbers correspond to similar or equivalent elements or features.

[0097] Figure 1 shows a first embodiment of a panel 100 according to the present invention. The figure shows a panel 100 which is obtained via a first possible embodiment of a method according to the present invention. The panel 100 comprises a substrate 101 comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern 102. The substrate is a primed substrate comprising a primer layer 103. A finishing layer is present too which comprises a primary coating layer 104 and a secondary coating layer 105. The panel 100 and in particular the finishing layer comprises a surface structure. In the shown embodiment, the surface structure extends into the primer layer 103. It is can be seen that the primary coating layer 104 and the secondary coating layer 105 fully extend over the surface of the panel 100.

[0098] Figure 2 shows a second embodiment of a panel 200 according to the present invention. The figure shows a panel 200 which is obtained via a second possible embodiment of a method according to the present invention. The panel 200 comprises a substrate 201 comprising an upper surface and a bottom surface,wherein at least part of the upper surface comprises a decorative pattern 202. The substrate is a primed substrate comprising a primer layer 203. A finishing layer is present too which comprises a plurality of primary coating layers 104a, 104b, 104c, 104d and a secondary coating layer 105. The primary coating layer 104 is textured by making use of a mask, wherefore part of the primary coating is fully removed.

[0099] It will be clear that the invention is not limited to the exemplary embodiments which are illustrated and described here, but that countless variants are possible within the framework of the attached claims, which will be obvious to the person skilled in the art. In this case, it is conceivable for different inventive concepts and / or technical measures of the above-described variant embodiments to be completely or partly combined without departing from the inventive idea described in the attached claims.

[0100] The verb 'comprise' and its conjugations as used in this patent document are understood to mean not only 'comprise', but to also include the expressions 'contain', 'substantially contain', 'formed by' and conjugations thereof.

[0101] As used herein, the term “about” is intended to account for measurement uncertainty and production tolerances. Unless stated otherwise, “about” has the following meanings: (i) for coefficient of friction (COF), “about” means ±0.05; (ii) for gloss level (Gu), “about” means ±1 Gu; (iii) for surface roughness parameters (Ra, Rz), “about” means ±10% of the stated value; (iv) for temperatures, “about” means ±5°C; (v) for viscosities, “about” means ±10% of the stated value; and (vi) for coating weights (g / m2), “about” means ±10% of the stated value.

Claims

1. Claims1. Method of producing a decorative panel, in particular a decorative floor, cladding, wall, or ceiling panel, comprising the steps of:a) providing at least one substrate, the substrate comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern;b) applying at least one at least partially uncured primer upon at least part of the upper surface of the substrate thereby forming a primed substrate; c) applying at least one uncured primary coating upon at least part of the primed substrate, thereby forming at least one primary coating layer; d) applying at least one texturing medium comprising at least one surface texture and / or at least one mask onto at least part of the at least one primary coating layer;e) at least partially curing at least part of the at least one primary coating layer such that a textured substrate is obtained;f) removing the at least one texturing medium and / or at least one mask; g) applying at least one at least partially uncured secondary coating upon at least part of the textured substrate, thereby forming at least one secondary coating layer;h) applying at least one secondary texturing medium comprising at least one secondary surface texture and / or at least one secondary mask onto at least part of the at least one secondary coating layer;i) at least partially curing at least part of the at least one secondary coating layer; andj) removing the at least one secondary texturing medium and / or at least one secondary mask.

2. The method according to claim 1 , wherein the at least one primary coating is at least partially flexible prior to curing, and preferably at least partially flexible after curing when tested according to ISO 48-4.

3. The method according to claim 1 or claim 2, wherein the at least one secondary coating differs from the at least one primary coating.

4. The method according to any of the preceding claims, wherein the at least one primary coating layer has a lower Shore D hardness than the at least one secondary coating layer.

5. The method according to any of the preceding claims, wherein curing of the at least one primary coating layer is done via radiation and wherein the at least one texturing medium is at least partially permeable for said radiation.

6. The method according to any of the preceding claims, wherein the at least one texturing medium comprises at least one negative surface texture and / or wherein the at least one secondary texturing medium comprises at least one secondary negative surface texture.

7. The method according to any of the preceding claims, wherein at least one texturing medium comprises an embossing roller and / or a textured foil.

8. The method according to any of the preceding claims, wherein the at least one texturing medium comprises at least one mask and / or wherein the at least one secondary texturing medium comprises at least one secondary mask.

9. The method according to any of the preceding claims, wherein the secondary coating has a viscosity of at least 1 ,500 mPas, preferably at least 2,000 mPas, and / or at most 8,000 mPas at time of application.

10. The method according to any of the preceding claims, wherein the method further comprises the step of aligning the at least one surface texture of the at least one texturing medium with at least part of the decorative pattern of the upper surface of the at least one substrate.

11. The method according to claim 10, wherein the at least one decorative pattern of the at least one substrate comprises at least one positioning marker and wherein the texturing medium is aligned with at least one positioning marker through a positioning step prior to and / or during step dand / or wherein the second texturing medium is aligned with at least one positioning marker though a positioning step prior to and / or during step h).

12. The method according to any of the preceding claims, wherein at least part of the at least one primary coating layer is at least partially cured after step c).

13. The method according to any of the preceding claims, wherein the at least one primer layer and / or at least one transparent primary coating layer comprises at least one abrasive additive selected from the group of aluminum oxide, corundum, quartz, silicon carbide, diamond particles, or any combination thereof.

14. The method according to any of the preceding claims, wherein the at least partially uncured primer has a viscosity of at least 5,000 mPa-s, preferably at least 6,000 mPa-s.

15. The method according to any of the preceding claims, wherein the at least partially uncured primer has a viscosity of at most up 8,000 mPa-s, preferably at most 10,000 mPa-s.

16. The method according to any of the preceding claims, wherein at least one primer layer, at least one primary coating layer and / or at least one secondary coating layer form a finishing layer, wherein the at least one finishing layer has a coefficient of friction (COF) of at least about 0.4, slip resistance performances of at least P3 tested according to AS 4586, and / or a pendulum slip resistance (PTV) of the at least one coating layer is at least 36, preferably at least 61 according to ISO BS 7976-2.

17. The method according to any of the preceding claims, wherein the at least one secondary coating comprises UV-curable acrylic, polyurethane, and / or polyester resins.

18. The method according to any of the preceding claims, wherein the at least one primary coating and / or secondary coating is UV curable and wherein at least one curing step of said primary coating layer and / or secondary coating layer involves the application of ultraviolet light, electron beam curing and / or excimer radiation.

19. The method according to any of the preceding claims, wherein the at least one texturing medium and / or the at least one secondary texturing medium has a wavelength cut-off in the range of 150 to 400 nm, preferably in the range of 240 to 380 nm and more preferably in the range of 280 to 315 nm.

20. The method according to any of the preceding claims, wherein the texturing step of the at least one texturing medium extends into at least part of at least one transparent primer layer of the primed substrate.

21. The method according to any of the preceding claims, wherein the transparent primer applied at step b) is at a temperature of at least 60 degrees Celsius, preferably at least 80 degrees Celsius.

22. The method according to any of the preceding claims, wherein the at least primer comprises polyurethane.

23. The method according to any of the preceding claims, wherein the at least one primer is applied in a quantity of at least 50g / m2, preferably at least 60g / m2, more preferably at least 70g / m2, and most preferably in a range of 80-100 g / m2 and at most 140 g / m2, preferably at most 120 g / m2.

24. The method according to any of the preceding claims, wherein the at least one primary coating is applied in a quantity of 5-20g / m2, preferably 8-15 g / m2 in particular at 25-35 degrees Celsius.

25. The method according to any of the preceding claims, wherein the at least one secondary coating is applied in a quantity of 5-20g / m2, preferably 8-15 g / m2 in particular at 25-35 degrees Celsius.

26. The method according to any of the preceding claims, wherein the primer layer is applied in a larger quantity and / or thickness compared to the first coating layer and / or the second coating layer, preferably in a ratio of at least 5:1, preferably at least 7.5:1 , most preferably at least 10:1.

27. The method according to any of the preceding claims, wherein the at least one primary coating comprises polyvinylchloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), polyethylene (PE), polyurethane (PU), acrylonitrile butadiene styrene (ABS) and / or co-polyester (CPE).

28. The method according to any of the preceding claims, wherein the at least one secondary coating comprises epoxy acrylate, polyurethane, 1 ,6-Hexanediol diacrylate, dipropylene glycol diacrylate, polyester acrylate resin, polyester polyol resin, polyester resin comprising acrylate and polyol functions, polyester acrylate resin with grafted hydroxyl groups, or combinations thereof.

29. The method according to any of the preceding claims, wherein at least steps e) and f) and / or steps i) and j) are reversed in order.

30. A decorative panel, in particular a floor panel, wall panel or ceiling panel, preferably obtained via the method according to any of the preceding claims, the panel comprising:- at least one primed substrate comprising an upper surface and a bottom surface, wherein at least part of the upper surface comprises a decorative pattern and at least one primer layer;;- a finishing layer, comprising:o at least one primary coating layer; ando at least one secondary coating layer;wherein the finishing layer comprises a surface structure; andwherein the surface roughness (Ra) of the at least one finishing layer is at least 4 pm, andwherein the at least finishing layer has a hardness of at least 75 Shore D.

31. The panel according to claim 30, wherein the panel has less than 0.1mm cupping when tested according to ISO 23999.

32. The panel according to claim 30 or 31 , wherein the at least one secondary coating layer has a surface roughness Ra of 1 urn, and / or has a COF of at least about 0.4 when tested to EN 14041.

33. The panel according to any of claims 30-32, wherein the finishing layer comprises at least partially a three-dimensional structure extending at least partially into said secondary coating layer, at least partially into said primary coating layer, and at least partially into said primer layer, wherein said three-dimensional structure has a depth ranging of at least 0.01mm, preferably at least 0.05mm to at most 0.2mm, preferably at most 0.3mm.

34. The panel according to claim 33, wherein said three-dimensional structure is at least partially synchronized with said at least one decorative layer.

35. The panel according to any of claims 30-34, wherein the surface structure is formed of a surface texture and a mechanical and / or deep embossing, wherein at least part of the mechanical and / or deep embossing extends into at least part of at least one primer layer.

36. The panel according to any of claims 30-35, wherein the surface roughness (Ra) of the at least one finishing layer is below or equal to 50 pm, preferably below or equal to 25 pm, more preferably below or equal to 15 pm.

37. The panel according to any of claims 30-36, wherein the finishing layer has a thickness of at least 0.05mm, most preferably at least 0.1 mm, and at most 0.5mm, most preferably at most 0.3mm38. The panel according to any of claims 30-37, wherein the panel comprises a core layer and at least one decorative top layer.

39. The panel according to any of claims 30-38, wherein the finishing layer has an abrasion resistance value of at least 4,000 cycles according to EN 13329.

40. The panel according to any of claims 30-39, wherein the panel has a deep scratch resistance of at least 2,000 g, in particular at last 2,200 g, more in particular at least 2,500 g, when tested to ISO 1518.

41. The panel according to any of claims 30-40, wherein the at least one finishing layer comprises at least one abrasive additive selected from the group ofaluminum oxide, corundum, quartz, silicon carbide, diamond particles, or any combination thereof.

42. The panel according to any of claims 30-41 , wherein the surface roughness (Ra) of the at least one finishing layer is at most 25 pm, preferably in the range of about 5 pm to about 15 pm.

43. The panel according to any of claims 30-42, wherein the average maximum height (Rz) of at least part of the texture of the at least one finishing layer is at least 15 pm and at most 28 pm, preferably in the range of about 17 pm to about 25 pm.

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